CN105529175A - Magnetic components and methods of manufacturing same - Google Patents
Magnetic components and methods of manufacturing same Download PDFInfo
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- CN105529175A CN105529175A CN201610087085.0A CN201610087085A CN105529175A CN 105529175 A CN105529175 A CN 105529175A CN 201610087085 A CN201610087085 A CN 201610087085A CN 105529175 A CN105529175 A CN 105529175A
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- 230000005291 magnetic effect Effects 0.000 title claims abstract description 185
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 47
- 238000000034 method Methods 0.000 title claims abstract description 45
- 239000004020 conductor Substances 0.000 claims abstract description 36
- 238000004804 winding Methods 0.000 claims abstract description 28
- 239000000463 material Substances 0.000 claims description 70
- 239000002245 particle Substances 0.000 claims description 40
- 239000008358 core component Substances 0.000 claims description 26
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 20
- 239000006247 magnetic powder Substances 0.000 claims description 19
- 239000011230 binding agent Substances 0.000 claims description 14
- 239000000843 powder Substances 0.000 claims description 12
- 239000000853 adhesive Substances 0.000 claims description 11
- 230000001070 adhesive effect Effects 0.000 claims description 11
- 230000035699 permeability Effects 0.000 claims description 11
- 229910052742 iron Inorganic materials 0.000 claims description 9
- 239000000203 mixture Substances 0.000 claims description 9
- 229910045601 alloy Inorganic materials 0.000 claims description 5
- 239000000956 alloy Substances 0.000 claims description 5
- VAWNDNOTGRTLLU-UHFFFAOYSA-N iron molybdenum nickel Chemical compound [Fe].[Ni].[Mo] VAWNDNOTGRTLLU-UHFFFAOYSA-N 0.000 claims description 5
- 229920005992 thermoplastic resin Polymers 0.000 claims description 5
- 229910000859 α-Fe Inorganic materials 0.000 claims description 5
- 239000010941 cobalt Substances 0.000 claims description 3
- 229910017052 cobalt Inorganic materials 0.000 claims description 3
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 3
- 229910017082 Fe-Si Inorganic materials 0.000 claims description 2
- 229910000863 Ferronickel Inorganic materials 0.000 claims description 2
- 229910017133 Fe—Si Inorganic materials 0.000 claims description 2
- 238000007493 shaping process Methods 0.000 claims 2
- 238000010438 heat treatment Methods 0.000 abstract 1
- 238000010030 laminating Methods 0.000 abstract 1
- 239000000696 magnetic material Substances 0.000 description 27
- 238000000465 moulding Methods 0.000 description 26
- 238000005516 engineering process Methods 0.000 description 12
- 230000004907 flux Effects 0.000 description 12
- 239000006249 magnetic particle Substances 0.000 description 11
- 238000009434 installation Methods 0.000 description 10
- 230000008859 change Effects 0.000 description 9
- 230000005415 magnetization Effects 0.000 description 8
- 230000008569 process Effects 0.000 description 8
- 239000000306 component Substances 0.000 description 7
- 230000008901 benefit Effects 0.000 description 6
- 230000002349 favourable effect Effects 0.000 description 6
- 230000015572 biosynthetic process Effects 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 238000010276 construction Methods 0.000 description 4
- 239000012212 insulator Substances 0.000 description 4
- 238000003475 lamination Methods 0.000 description 4
- 229910000679 solder Inorganic materials 0.000 description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- 230000000712 assembly Effects 0.000 description 2
- 238000000429 assembly Methods 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
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- 229910052802 copper Inorganic materials 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 238000007598 dipping method Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- XWHPIFXRKKHEKR-UHFFFAOYSA-N iron silicon Chemical compound [Si].[Fe] XWHPIFXRKKHEKR-UHFFFAOYSA-N 0.000 description 2
- 239000000178 monomer Substances 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 229910000702 sendust Inorganic materials 0.000 description 2
- 241001391944 Commicarpus scandens Species 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
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- UGKDIUIOSMUOAW-UHFFFAOYSA-N iron nickel Chemical compound [Fe].[Ni] UGKDIUIOSMUOAW-UHFFFAOYSA-N 0.000 description 1
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0233—Manufacturing of magnetic circuits made from sheets
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/33—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials mixtures of metallic and non-metallic particles; metallic particles having oxide skin
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/10—Composite arrangements of magnetic circuits
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/041—Printed circuit coils
- H01F41/046—Printed circuit coils structurally combined with ferromagnetic material
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/0006—Printed inductances
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
- H01F2017/048—Fixed inductances of the signal type with magnetic core with encapsulating core, e.g. made of resin and magnetic powder
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/2847—Sheets; Strips
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
- Y10T29/49073—Electromagnet, transformer or inductor by assembling coil and core
Abstract
The invention discloses a method for manufacturing magnetic part component. The method comprises the following steps: providing at least one prefabricated layer made of magnetic sheets, providing at least one prefabricated coil, wherein the prefabricated coil is confined by an independent coil conductor, the prefabricated coil comprises a winding part with a central opening, and the prefabricated coil is independently manufactured related to at least one prefabricated layer made of magnetic sheets; laminating the prefabricated layer made of magnetic sheets by pressure without heating so as to contact the winding part so as to finish a magnetic body comprising the winding part and the central opening.
Description
The application is application number is 201080028152.2 (PCT/US2010/032414), and the applying date is on 04 26th, 2010, and denomination of invention is the divisional application of the application for a patent for invention of " magnetic part and manufacture method thereof ".
Background technology
Field of the present invention generally relates to magnetic part and manufacture thereof, and more properly relates to the magnetic surface mounting electronic parts of such as inductor and transformer and so on.
Along with the progress of Electronic Packaging, manufacture less but the more powerful electronic installation of tool has become feasible.In order to reduce the overall dimension of these electronic installations, the electronic unit for the manufacture of these electronic installations has become day by day miniaturized.Manufacture electronic unit meets these demands and there is many difficulties, therefore makes manufacturing process costly, and undesirably increases the cost of electronic unit.
Be similar to other parts such, the manufacturing process for the magnetic part of such as inductor and transformer and so on is carefully examined, to reduce the cost of the electronics manufacturing of high competition.When manufactured electronic unit is low cost and is the parts of high power capacity, the reduction for manufacturing cost is particularly desirable.At these electronic units and use in the high power capacity large-scale production process of electronic installation of these electronic units, that yes is significant for any reduction of manufacturing cost.
Accompanying drawing explanation
Describe nonrestrictive and non exhaustive embodiment with reference to the following drawings, wherein, except as otherwise noted, in the drawings and in which, similar Reference numeral represents like.
Fig. 1 is the decomposition view of the first example magnetic part assembly formed according to the present invention one exemplary embodiment.
Fig. 2 is the stereogram of the first example coils for the assembly of magnetic part shown in Fig. 1.
Fig. 3 is the cutaway view of the wire of coil shown in Fig. 2.
Fig. 4 is the stereogram of the second example coils for the assembly of magnetic part shown in Fig. 1.
Fig. 5 is the cutaway view of the wire of coil shown in Fig. 4.
Fig. 6 is the stereogram of the second example magnetic part assembly formed according to the present invention one exemplary embodiment.
Fig. 7 is the stereogram of the 3rd example magnetic part assembly formed according to the present invention one exemplary embodiment.
Fig. 8 is the assembly drawing of parts shown in Fig. 7.
Embodiment
This document describes the example embodiment of the electronic unit design of original creation, these electronic units overcome the various difficult problems of this area.In order to the most intactly understand the present invention, below disclose and have different portions section or part, wherein part I discusses particular problem and a difficult problem, and the exemplary components that part II describes for overcoming these problems constructs and assembly.
I. introduction of the present invention
The traditional magnetic parts for board application of such as inductor and so on generally include magnetic core and are positioned at the conductive winding (sometimes referred to as coil) of magnetic core.Core can be made up of discrete core components, and these core components are made up of magnetic material, are placed between core components by winding simultaneously.The core components of various shape and type and assembly are known for those skilled in the art, comprise but are not necessarily limited to the shape of U core and I-core assembly, ER core and I-core assembly, ER core and ER core assembly, pot-shaped core portion and T core assembly and other coupling.These discrete core components can utilize adhesives together, and usually spaced physically or spaced apart.
Such as, in the parts that some are known, coil is made up of conductive wire, and this conductive wire is wound in core or terminal clip.That is, after core components is fully formed, wire can around core components, and this core components is sometimes referred to as cylinder core or bobbin core.Each free end of coil can be called lead-in wire, and can be used for via being attached directly to circuit board or through the indirect connection of terminal clip, inductor being connected in circuit.Especially for less core components, with cost, effectively and reliable mode reels, coil is challenging.Winding by hand parts are tending towards unstable at their aspect of performance.The shape of core components causes them quite fragile, and when reeling coil, core is easy to break, and the gap change between core components can make component capabilities produce undesirable change.An another difficult problem is: DC impedance (" DCR ") can due in winding process, winding and tension force and undesirably changing unevenly.
In other known elements, the coil that known surface installs magnetic part is made usual separating with core components, and assembles with core components afterwards.That is, these coils are considered to be preformed or pre-wound sometimes, the problem produced to avoid manual wound coil, and the assembling simplifying magnetic part.These preformed coil are for especially favourable less part dimension.
In order to when by magnetic part surface be installed on circuit board time, carry out the electrical connection with coil, conducting terminal or wire clamp are provided usually.Wire clamp is assembled on shaped core parts, and is electrically connected on the respective end of coil.Terminal clip generally includes the substantially smooth and region of plane, and these regions example solder as is known (soldering) technology can be electrically connected on conductive trace on circuit board and pad.When so attached and when circuit board is energized, electric current can flow to one of them terminal clip from circuit board, flow to another terminal clip and be back to circuit board by coil.In the situation of inductor, the electric current flowing through coil can respond to generation magnetic field and magnetic energy in magnetic core.More than one coil can be provided.
In the situation of transformer, be provided with primary coil and secondary coil, the electric current wherein flowing through primary coil responds to generation current in secondary coil.The manufacture of transformer part has the problem similar with inductor components.
For day by day miniaturized parts, it is challenging for being provided in physically isolated core.Be difficult to come in a cost efficient manner reliably to realize setting up and maintain constant clearance size.
About installing in magnetic part on the surface of miniaturization, carrying out also there is multiple practical problem in electrical connection between coil and terminal clip.Suitable rapid wear connection between coil and terminal clip is carried out in core outside usually, and therefore fragile separately time.In some cases, known the part of overhang around wire clamp to be wound around, to guarantee positive mechanical between coil and wire clamp and electrical connection.But from manufacture angle, this has been proved to be loaded down with trivial details, and more easily and faster termination schemes can be desirable.In addition, the winding of end winding is inapplicable for the coil of some type, such as, have the coil of the rectangular cross section with flat surfaces, and this kind of coil does not have the flexibility as the thin and wire configurations of circle.
Along with electronic installation continues to become the recent trend of high-power day by day, also need the magnetic part of such as inductor and so on to conduct the magnitude of current of increase.So, usually increase the wire gauge for the manufacture of coil.Because the size of the wire for the manufacture of coil increases, when round conductor is for the manufacture of coil, end is flattened to suitable thickness and width usually, carries out machinery and be electrically connected with Application Example satisfactorily as solder, melting welding or electroconductive binder and so on terminal clip.But wire gauge is larger, then be more difficult to overhang to flatten, suitably these ends are connected to terminal clip.These difficult problems have caused unstable connection between coil and terminal clip, and this can in use make magnetic part produce undesirable performance issue and change.Reduce this kind of change and be proved to be very difficult and cost.
For some application, manufacture coil by flat but not circular conductive body and can alleviate these problems, but first flat electric conductor is tending towards more rigid and is more difficult to be configured as coil, therefore causes other manufacturing issue.Contrary with circular conductive body, use flat electric conductor also sometimes undesirably in use can change the performance of parts.In addition, in some known configuration, especially those comprise in the structure of the coil become by Flat conductive system, and the termination aspect of such as hook or other architectural feature and so on can be formed in overhang so that with the connection of terminal clip.But, these features are formed in overhang and can cause further expense in a manufacturing process.
Their power is increased again and the new trend of capacity still exists more challenge for the size reducing electronic installation.Along with the size of electronic installation reduces, size for the electronic unit in these electronic installations must correspondingly reduce, therefore attempted to manufacture power inductor and transformer economically, and these power inductors and transformer have relatively little, be microminiaturized structure sometimes, but carrying increases the magnitude of current comes for electronic circuitry.Magnetic core structure has much lower profile (profile is low) relative to circuit board ideally, to obtain elongated and sometimes very thin electronic installation profile.Meet these demands and also there is more difficulty.For the parts being connected to multi-phase power system, also there is some other difficult problem, the out of phase wherein holding power supply in miniaturization device is difficult.
Attempt to make the basal surface of magnetic part and contour optimization, for the component manufacturer expecting to meet the size requirements of modern electronics, there is larger meaning.Each parts on circuit board can be limited by vertical width measured in the plane being parallel to circuit board and depth dimensions usually, the product of this width and the degree of depth determines that this surface area is sometimes referred to as " basal surface (area coverage) " of parts by parts surface area occupied on circuit boards.On the other hand, along be orthogonal to or perpendicular to circuit board direction measured by parts height overall sometimes referred to as " profile " of parts.The basal surface of parts partly defines how many parts and can install on circuit boards, and the space that outline portion ground is determined in an electronic, allowed between parallel circuit board.Less electronic installation usually needs to there are more parts and is installed on each circuit board, reduces the gap between adjacent circuit plate, or need simultaneously above-mentioned both.
II. the creative magnetic part assembly of example and manufacture method thereof
The various embodiments of magnetic core component described below comprise magnetic structure and coil structure, and provide the manufacture and assembling advantage that are better than the existing magnetic core component for board application.Can provide these advantages from hereinafter it should be understood that, be because used magnetic material can be molded on coil at least in part, eliminates the step of assembling discrete, isolated core and coil thus.In addition, magnetic material has Distributed gaps characteristic, which avoid any demand for the different component physicals of magnetic material are separated or separated.Like this, advantageously avoid and set up and maintain the difficulty and expense that consistent physical clearance size is associated.Also have other advantage to be partly apparent, and partly point out hereinafter.
The manufacturing step part be associated with described device is apparent and part is hereafter describing definitely.Similar, the device section be associated with described method step is apparent and part is hereafter describing definitely.That is, apparatus and method of the present invention will there is no need to describe respectively in the following description, and be believed suitably in the scope of human knowledge of those skilled in the art, and without the need to further explanation.
Referring now to Fig. 1, manufacture magnetic part assembly 100 with layered structure, wherein in batch process, multiple layer is stacking and fit together.
Shown assembly 100 comprises multilayer, and these layers comprise external magnetic layer 102 and 104, internal magnetization layer 106 and 108 and coil layer 110.Internal magnetization layer 106 and 108 is positioned on the relative both sides of coil layer 110, and coil layer 110 is pressed from both sides between which.External magnetic layer 102 and 104 is positioned at internal magnetization layer 106 with on the surface relative with coil layer 110 of 108.
In an example embodiment, each in magnetosphere 102,104,106 and 108 is by can made by molding magnetic material, this can molding magnetic material can be such as have the magnetic powder particles of Distributed gaps characteristic and the mixture of polymeric binder, as understandable undoubtedly in the art.Therefore, magnetosphere 102,104,106 and 108 can be suppressed around coil layer 110 and be pressed against each other, with above coil layer 110, below and around the magnetic 112 of shape all-in-one-piece or monomer.Although illustrate four magnetospheres and a coil layer, it will be appreciated that other and/or substitute embodiment in can use the magnetosphere of more or less quantity and the coil layer 110 more than.
In an example embodiment, for the manufacture of magnetospheric material, there is the relative permeability μ much larger than
r, thus make miniaturized power inductor parts produce enough inductance value.Or rather, in an example embodiment, magnetic permeability μ
rcan be at least 10.0 or higher.
As shown in Figure 1, multiple coils of winding are also referred to as when coil layer 110 includes.Any amount of coil can be used in coil layer 110.Coil in coil layer 110 can by any way, including, but not limited to those modes described in the same related application all by the applicant of institute's reference above made by electric conducting material.Such as, the coil layer 110 in different embodiment can be formed, or is formed on rigidity or flexible base material by printing technology and so on each via the flat wire electric conductor of the multi-turn that reels around axis, the multi-turn round conductor electric conductor that to reel around axis.
Each coil in coil layer 110 can comprise any amount of circle circle or wire loop, comprise the local being less than a complete circle circle or part wire turn, to realize desired magnetic effect, and the inductance value of such as magnetic part.Circle circle or wire loop can be included in they end link multiple straight-line conductive paths, arc conductive path, spiral conductive path, snakelike conductive path or other other known form and structure.Coil in coil layer 110 can be formed as substantially flat element, or is alternately formed as three-dimensional free-standing coil part.Use in the situation of free-standing coil part the latter, freestanding element can be connected in lead frame for the ease of manufacture.
In various embodiments, the magnetic powder particles for the formation of these magnetospheres 102,104,106 and 108 can be ferrite particle, iron particle, iron sial (Sendust) particle, nickel-molybdenum iron (MPP) particle, ferronickel (HighFlux) particle, ferro-silicium (Megaflux) particle, iron-based amorphous powder particle, cobalt-based amorphous powder particle or other equivalent material known in the art.When these magnetic powder particles mix with polymer binder material, synthesized magnetic material presents Distributed gaps characteristic, and this characteristic avoids for physical clearance or any needs of different magnetic material pieces of separating.Like this, advantageously avoid and set up and maintain the difficulty and expense that consistent physical clearance size is associated.For the application of high electric current, magnetic amorphous metal powder that combine with polymeric binder, preannealing is considered to favourable.
In various embodiments, magnetosphere 102,104,106 can made by the magnetic-particle of identical type or dissimilar magnetic-particle with 108.That is, in one embodiment, all magnetospheres 102,104,106 can made by the magnetic-particle of a kind of or identical type with 108, even if making these magnetospheres 102,104,106 and 108 have not identical is also substantially similar magnetic.But in another embodiment, one or more layers in magnetosphere 102,104,106 and 108 can made by the magnetic powder particles dissimilar with other magnetosphere.Such as, internal magnetization layer 106 and 108 can comprise the magnetic-particle dissimilar with external magnetic layer 102 and 104, makes internal magnetization layer 106 and 108 have the magnetic different from external magnetic layer 102 and 104.Therefore, complete parts performance characteristic can change according to used magnetosphere quantity with for the formation of the type of each magnetospheric magnetic material.
Various formulas for the formation of the magnetic composite of plate 102,104,106 and 108 can realize making element in use have the magnetic of various level.But, usually in power inductor application, the magnetic of material substantially with the heap(ed) capacity (percentage by weight) of the magnetic-particle in the magnetic permeability (μ) of the flux density saturation point (Bsat) of the magnetic-particle be used in magnetosphere, magnetic-particle, magnetosphere and magnetosphere as described below be compressed on around coil after bulk density proportional.That is, by increasing magnetic saturation point, magnetic permeability, heap(ed) capacity and bulk density, higher inductance value can be obtained and can performance be improved.
On the other hand, the magnetic of element is inversely proportional to the jointing material amount be used in each magnetosphere 102,104,106 and 108.Therefore, along with the heap(ed) capacity of jointing material increases, the inductance value of final parts is tending towards reducing, and the overall magnetic of parts also reduces.Each in Bsat and μ is the material behavior be associated with magnetic-particle, and can change between dissimilar particle, and the heap(ed) capacity of the heap(ed) capacity of magnetic-particle and binding agent can change between the magnetosphere of different formulations.
For inductor components, above-mentioned consideration can be used for strategically selection material and layer formula, to realize specific object.As an example, metal powder material can be better than Ferrite Material, and is used as said magnetic powder material in the inductor application of higher-wattage, and this is because the metal dust of such as iron-silicon grain and so on has higher Bsat value.Bsat value refer to by apply external magnetic field strength H and can in magnetic material available peakflux density B.Magnetization curve can disclose the Bsat value of any given material, and this magnetization curve is called BH curve sometimes, wherein in the scope of magnetic field intensity H, draws magnetic flux density B.The initial part of BH curve limits magnetic permeability or the tendency of material to be magnetized.Bsat refer in BH curve a bit, set up magnetization or the magnetic flux maximum rating of material at this place, even and if magnetic field intensity continues to increase, magnetic flux keeps constant more or less.In other words, B-H arrive and maintain minimum slope a bit represent flux density saturation point (Bsat).
In addition, the such as metal powder granulates of iron-silicon grain and so on has relatively high-caliber magnetic permeability, and such as the Ferrite Material of iron nickel (the saturating alloy of magnetic) and so on has relatively low magnetic permeability.Generally speaking, in the BH curve of the metallic particles used, the changing rate of permeability is larger, then composite material is by magnetic flux with generate the energy in magnetic field producing magnetic flux to be held in the ability of specific present level larger.
As shown in Figure 1, magnetosphere 102,104,106 and 108 can be arranged to relatively thin plate, and these plates can or carry out stacking and connected to each other in lamination process via other technology as known in the art and coil layer 110.As used herein, term " stacked " should refer to following process: wherein magnetosphere links or is integrated into sandwich construction, and after being linked and integrating, remain discernible each layer.In addition, can thermoplastic resin be comprised for the manufacture of magnetospheric polymeric binder material, and thermoplastic resin to allow to carry out pressure to powder plate in lamination process, under the condition do not heated stacked.Therefore, the expense that the intensification eliminating the heat lamination required for the stacking material known with other is associated and cost, thus pressure stacked be favourable.Magnetic sheet can be placed in mould or other pressure vessel and to compress, and is laminated to each other to make Magnaglo plate.Magnetosphere 102,104,106 and 108 can be made in advance in the independent fabrication stage, to simplify the formation of magnetic part in the follow-up assembling stage.
In addition, magnetic material such as can be molded as desired shape by compression molded technology or other technology valuably, magnetosphere is connected in coil and magnetic is defined as desired shape.It is favourable for can carrying out molded to magnetic material, and this is because magnetic can be formed as comprising around coil layer 110 one or the monomer structure of coil, and avoids separate manufacturing step coil groups being filled to magnetic texure.The magnetic of various shape can be provided in various embodiments.
Once element 100 is fixed together, this assembly 100 can cutting, cutting, single point (singulated) or be otherwise divided into discrete separate part.Each parts can be the small piece of substantial rectangular, but other distortion is also fine.Each parts can comprise single coil or multiple coil according to desired final utilization or application.Can before or after parts coverlet divides, for assembly 100 provide such as the related application by introducing see mode or mentioned above described in the surface mount ends access node structure of any one end on structure and so on.These parts can use known solder technology and so on to be installed on the surface of circuit board, to set up electrical connection between the coil in circuit on circuit boards and magnetic part.
These parts can specifically be suitable for being used as transformer or inductor in direct current (DC) application of power, the application of single-phase voltage inverter power supply, the application of two-phase voltage inverter power supply, three-phase voltage changer application of power and polyphase source application.In various embodiments, coil can be electrically connected in series or in parallel, to realize different objects in parts itself or via the circuit it is provided with in the circuit board of these coils.
When two or more absolute coil is located in a magnetic part, coil can be arranged so that between these coils, there is magnetic flux shares.That is, these coils utilize the common flux paths by single magnetic each several part.
Be produced in batches technique although shown in Figure 1, it should be understood that if necessary, other manufacturing process can be used to manufacture independent discrete magnetic parts.That is, can molding magnetic material can such as only be compressed on around the coil of desired quantity of single assembly.As an example, polyphase source is applied, molding magnetic material can being compressed on around two or more independent coil, provide magnetic and the loop construction of one, and the magnetic of this one and loop construction completing by adding any required end on structure.
Fig. 2 is the stereogram of the first example lead loop 120, and this lead loop can be used for constructing such as those magnetic parts mentioned above.As shown in Figure 2, lead loop 120 comprises the opposed end 122 and 124 sometimes referred to as lead-in wire, and coil assembly 126 extends between end 120 and 122.Line conductor for the manufacture of coil 120 can made by copper or another conducting metal known in the art or alloy.
Wire can be wound in around axis 128 in a known way flexibly, to provide the windings section 126 with multiple circle circle, thus the effect desired by realizing, such as parts inductance value desired by selected final utilization or application.Those skilled in the art it should be understood that the inductance value of windings section 126 depends primarily on the cross-sectional area of the number of turn of wire, the certain material for the manufacture of the wire of coil and the wire for the manufacture of coil.So by changing the cross-sectional area of coil turn, wire turn structure and coil wire turn, the inductance rated value of magnetic part can change significantly for different application.Many coils 120 can manufacture in advance and be connected to lead frame, to form coil layer 110 (Fig. 1.
Fig. 3 is the cutaway view of end winding 124, and the another feature (Fig. 2) for the manufacture of the wire of coil 120 is shown.Although only illustrate an end winding 124, it should be understood that whole coil is provided with similar feature.In other embodiments, in the some parts of coil, the feature shown in Fig. 3 can be provided with in not all part.As an example, the feature shown in Fig. 3 can be provided with at windings section 126 (Fig. 2) in end 122,124.Other distortion is equally also possible.
Line conductor 130 is can be observed in the center of cross section.In the example depicted in fig. 3, line conductor 130 is circular substantially on cross section, and line conductor is referred to as round conductor sometimes thus.Insulating barrier 132 can arrange on online conductor 130, to avoid the electrical open of wire and adjacent magnetic powder particle in completed assembly, and in the fabrication process for coil provides protection to a certain degree.Can adopt in a known manner, any insulating material being enough to realize this object is set including, but not limited to coating technology or dipping technique.
In addition, as shown in Figure 3, adhesive 134 is also provided.In the manufacture process of element, adhesive can be intensified by heat shock or chemistry alternatively.This binding agent provides structural strength additional between coil and magnetic and globality valuably and improves caking property.Any known mode can be adopted, the binding agent being applicable to this object is set including, but not limited to coating technology or dipping technique.
Although insulator 132 and adhesive 134 are favourable, can imagine in various embodiments, they can be considered to optional, both namely selecting individually and jointly.That is, insulator 132 and/or adhesive 134 are without the need to being present in all embodiments.
Fig. 4 is the stereogram of the second example lead loop 140, and this lead loop can replace coil 120 (Fig. 2) and for magnetic part assembly (Fig. 1).As shown in Figure 4, lead loop 140 comprises the opposed end 142 and 144 sometimes referred to as lead-in wire, and coil assembly 146 extends between end 142 and 144.Line conductor for the manufacture of coil 140 can made by copper or another conducting metal known in the art or alloy.
Wire can be wound in around axis 148 in a known way flexibly, to provide the windings section 146 with multiple circle circle, thus the effect desired by realizing, the selected final utilization of institute such as reached for parts apply desired by inductance value.
As shown in Figure 5, can be observed line conductor 150 in the center of cross section.In the example depicted in fig. 5, line conductor 150 is elongated with rectangle substantially on cross section, and has sidepiece that is relative and smooth and plane substantially.Therefore, line conductor 150 is called flat wire sometimes.High temperature insulator 132 and/or adhesive 134 can be provided with as mentioned above alternatively and there is similar advantage.
The line conductor of other shape other can be used for manufacturing coil 120 or 140.That is, if necessary, wire without the need to being circular or smooth, and can have other shape.
Fig. 6 illustrates another magnetic part assembly 160, this assembly substantially comprise limit magnetic 162 can molding magnetic material and be connected to the lead loop 164 of multiple multiturn circles of this magnetic.Be similar to aforesaid embodiment, magnetic 162 can be suppressed around coil 164 with relatively simple manufacture process.Coil 164 is spaced and can operate independently in magnetic 162 in magnetic.As shown in Figure 6, although provide three lead loop 164, the lead loop 164 of more or less quantity can be provided in other embodiments.In addition, although the coil 164 shown in Fig. 6 is made by the line conductor of circle, the coil of other type is alternately used, including, but not limited to those coils described herein or any coil in related application noted above.Coil 164 can be provided with high temperature insulator mentioned above and/or adhesive alternatively.
What limit magnetic 162 can molding magnetic material can be any one in above-mentioned material or other suitable material known in the art.Although the said magnetic powder material being mixed with adhesive is considered to favourable, for make magnetic material formed magnetic 162, powder particle or non magnetic adhesive all optional.In addition, can molding magnetic material without the need to being arranged to above-mentioned plate or layer, but compression molded technology or other technology known in the art can be used directly to be connected in coil 164.Although the body 162 shown in Fig. 6 normally elongated with rectangle, the magnetic 164 of other shape is also fine.
Coil 164 can be located in magnetic 162, makes to there is magnetic flux between which and shares.That is, adjacent windings 164 can share the common flux paths by magnetic each several part.
Fig. 7 and 8 illustrates another miniaturized magnetic part assembly 170, and this assembly comprises the magnetic powder material limiting magnetic 172 and the coil 120 connected with this magnetic substantially.Magnetic 172 by coil 120 side can moulding magnetic layer 174,176,178 and coil 120 opposite side can made by moulding magnetic layer 180,182,184.Although illustrate six layers of magnetic material, it will be appreciated that other and/or substitute embodiment in more or less magnetic number of plies can be set.Also can imagine, in certain embodiments, the veneer of such as upper plate 178 and so on can limit magnetic 172, and without the need to using other plate any.
In an example embodiment, magnetosphere 174,176,178,180,182,184 can to comprise in all dusty materials as described above or magnetic powder material known in the art any one magnetic powder material.Although multi-layered magnetic material shown in Figure 7, this pulverous magnetic material can be suppressed in powder form alternatively or otherwise be connected to coil, and forms each layer as above without the need to prefabrication step.
All layers 174,176,178,180,182,184 can be made up of identical magnetic material in one embodiment, even if to make these layers 174,176,178,180,182,184 have be not identical is also similar magnetic properties.In another embodiment, one or more layers in layer 174,176,178,180,182,184 can be made by from other layer of different magnetic material in magnetic bodies 172.Such as, layer 176,180 and 184 can be made by moulding material by first with the first magnetic properties, and layer 174,178 can be made by moulding material by second with the second magnetic properties different from the first magnetic properties with 182.
Be different from aforesaid embodiment, magnetic part assembly 170 comprises the moulding core element 186 inserted by coil 120.In the exemplary embodiment, moulding core element 186 can be made up of the magnetic material different from magnetic 172.Moulding core element 186 can be made up of any material as known in the art, includes but not limited to already described those.As shown in Fig. 7 and 8, moulding core element 186 can be shaped as the general cylindrical shape with the shape complementarity of the central opening 188 of coil 120, but also can imagine, and the shape of non-cylindrical can similarly for having the coil of non-cylindrical opening.In other embodiment other, moulding core element 186 and coil aperture need not have complementary shape.
Moulding core element 186 can extend across the opening 188 in coil 120, and then can molding magnetic material be molded into around coil 120 and moulding core element 186, to complete magnetic 172.When the material selected for moulding core element 186 have than for the formation of magnetic bodies 172 can molding magnetic material better characteristic time, the different magnetic properties of moulding core element 186 and magnetic bodies 172 can be particularly advantageous.Therefore, the magnetic flux path through core component 186 can provide than magnetic bodies otherwise the better performance that will provide.If compared with whole magnetic is made up of the material of moulding core element 186, can the manufacture advantage of molding magnetic material be to realize lower component costs.
Although illustrated a coil 120 and core component 186 in Fig. 7 and 8, more than one coil also can be imagined and coil part can be arranged in magnetic 172 similarly.In addition, those types above-mentioned are included but not limited to or the coil of other type of those types in the related application pointed above can replace coil 120 to use as required.
Surface mount ends access node structure also can be located on magnetic part assembly 170, to provide the parts of the platelet-type being similar to those parts of this area.This kind of surface mount ends access node structure can comprise herein by any end on structure pointed in the related application introduced see mode or other end on structure known in the art.Therefore, element 170 can use surface mount ends access node structure and known technology to be installed on circuit board.Therefore, the element 170 of miniaturized low profile is convenient to make the high performance magnetic parts of relative high powers in larger circuit board assemblies, occupy relatively little space (in basal surface and profile), and allows the size reducing circuit board assemblies further.Therefore, the more high-power but less electric device comprising circuit board can be realized.
III. disclosed exemplary embodiment
Can think now, benefit of the present invention is apparent by aforementioned exemplary and embodiment.
One example embodiment of magnetic part assembly comprises: stepped construction, comprising: the preformed layer of at least one magnetic sheet material; And at least one prefabricated coil; At least one preformed layer is compressed on around prefabricated coil, forms the single-piece magnetic holding coil thus.In magnetic, do not form physical clearance, and this assembly can power limitation inductor.
Optionally, the preformed layer of at least one magnetic sheet material comprises the mixture of magnetic powder particles and polymeric binder.Magnetic-particle can be selected from the group of ferrite particle, iron particle, iron sial (Sendust) (Fe-Si-Al) particle, nickel-molybdenum iron (MPP) (Ni-Mo-Fe) particle, dilval (HighFlux) (Ni-Fe) particle, ferro-silicium (Megaflux) (Fe-Si alloy) particle, iron-based amorphous powder particle, cobalt-based amorphous powder particle and equivalent and their combination.The preformed layer of at least one magnetic sheet material can comprise at least two-layer magnetic sheet material, and at least one prefabricated coil is clipped between at least two-layer magnetic sheet material.At least two-layer magnetic sheet material can the dissimilar magnetic powder particles of each freedom be made, and at least two-layer thus in multi-layered magnetic plate material has magnetic properties different from each other.
At least one preformed layer of magnetic sheet material can have the relative permeability being greater than about 10.Polymeric binder can be thermoplastic resin.
Coil can limit central opening, and element also can comprise patterned magnetic core component.Patterned magnetic core component can provide individually with moulding core element, and is assemblied in central opening.The preformed layer of at least one magnetic sheet material can comprise at least two-layer magnetic sheet material, and at least one prefabricated coil is clipped between at least two-layer magnetic sheet material, and patterned magnetic core component is also clipped between at least two-layer magnetic sheet material.Patterned magnetic core component can be substantially columniform.
Coil can comprise line conductor, and this line conductor to reel multi-turn around axis, flexibly to limit windings section.Line conductor can be circular or flat.At least one in straight-line conductive path, arc conductive path, spiral conductive path and snakelike conductive path that the end that multiple wire turn can be included in them links.Coil can be configured as three-dimensional, free-standing coil part.Coil can be provided with adhesive.This coil can be connected to lead frame.
Also disclose a kind of method manufacturing magnetic part.Parts comprise coil windings and magnetic, and the method comprises thus: be compressed on by the preformed layer of at least one magnetic sheet material around at least one prefabricated coil winding, form the stacked magnetic holding coil windings thus.
Compression molding can not relate to heat lamination.Coil windings can comprise central opening, and the method also can comprise the moulding core element made separately is put on central opening.
Product is obtained by the method.The preformed layer of at least one magnetic sheet material can have the relative permeability at least about 10.The preformed layer of at least one magnetic sheet material can comprise the mixture of magnetic powder particles and polymeric binder.Polymeric binder can be thermoplastic resin.The preformed layer of at least one magnetic sheet material can comprise at least two-layer magnetic sheet material, and this at least two-layer magnetic sheet material comprises dissimilar magnetic-particle and has different magnetic properties thus.This product can be miniaturized power inductor.
This written description uses example to disclose the present invention comprising optimal mode, and for making any person skilled in the art put into practice the present invention, comprising and manufacture and use any equipment or system and implement any comprised method.The patentable scope of the present invention limited by claim, and can comprise other example expected by those skilled in the art.If some other examples have not different from the literal language of claim structural details, or these examples comprise and do not have the equivalent structural elements of essential distinction with the literal language of claim, then these examples still can be considered to drop in the scope of these claims.
Claims (19)
1. manufacture a method for magnetic part assembly, comprising:
The preformed layer of at least one magnetic sheet material is provided;
At least one prefabricated coil is provided, at least one prefabricated coil described is limited by free-standing coil-conductor, it is formed as the windings section comprising central opening, and the preformed layer of at least one prefabricated coil wherein said at least one magnetic sheet material relatively described independently manufactures; And
Under the condition do not heated, pressure carries out to the preformed layer of at least one magnetic sheet material described stacked, make it the magnetic having contacted to comprise described windings section and described central opening with described windings section.
2. the method for claim 1, is characterized in that, the preformed layer magnetic sheet material providing the preformed layer of at least one magnetic sheet material to comprise the mixture being provided as magnetic powder particles and polymeric binder.
3. method as claimed in claim 2, it is characterized in that, the preformed layer magnetic sheet material being provided as the mixture of magnetic powder particles and polymeric binder comprises the magnetic sheet material providing and have the magnetic powder particles being selected from following group, and described group is ferrite particle, iron particle, iron sial (Fe-Si-Al) particle, nickel-molybdenum iron (Ni-Mo-Fe) particle, ferronickel (Ni-Fe) particle, ferro-silicium (Fe-Si alloy) particle, iron-based amorphous powder particle, cobalt-based amorphous powder particle and equivalent and their combination.
4. method as claimed in claim 2, it is characterized in that, there is provided the preformed layer of at least one magnetic sheet material to comprise the preformed layer providing at least two-layer magnetic sheet material, and described method also comprise at least one prefabricated coil described is clipped in described at least two-layer magnetic sheet material preformed layer between.
5. method as claimed in claim 4, it is characterized in that, the preformed layer of at least one magnetic sheet material is provided to comprise the preformed layer providing at least two-layer magnetic sheet material, the magnetic powder particles that each freedom of preformed layer of described at least two-layer magnetic sheet material is different is made, and presents magnetic properties different from each other.
6. method as claimed in claim 2, it is characterized in that, the preformed layer magnetic sheet material being provided as the mixture of magnetic powder particles and polymeric binder comprises the preformed layer magnetic sheet material of the mixture being provided as magnetic powder particles and thermoplastic resin.
7. the method for claim 1, is characterized in that, providing the preformed layer of at least one magnetic sheet material to comprise provides the preformed layer of at least one magnetic sheet material with the relative permeability being greater than about 10.
8. the method for claim 1, is characterized in that, also comprises:
There is provided shaping magnetic core element, at least one in the preformed layer of described patterned magnetic core component at least one magnetic sheet material relatively described and at least one preformed layer described independently manufactures; And
Wherein, the described pressure carried out under the condition do not heated is stacked, to complete the magnetic comprising described patterned magnetic core component.
9. method as claimed in claim 8, is characterized in that, also comprise being assemblied in described patterned magnetic core component at least partially in described central opening.
10. method as claimed in claim 9, is characterized in that, provide the preformed layer of at least one magnetic sheet material described to comprise the preformed layer providing at least two-layer magnetic sheet material, described method also comprises:
Between the preformed layer of at least two-layer magnetic sheet material described in the described patterned magnetic core component of at least one prefabricated coil described is clipped in.
11. methods as claimed in claim 9, is characterized in that, provide shaping magnetic core element to comprise and provide columniform patterned magnetic core component.
12. the method for claim 1, is characterized in that, providing at least one prefabricated coil to comprise provides the line conductor of flexibility to make described line conductor around axis around described central opening winding multi-turn.
13. methods as claimed in claim 12, is characterized in that, provide flexible line conductor to comprise the line conductor providing and have circular cross-section.
14. methods as claimed in claim 12, is characterized in that, provide flexible line conductor to comprise the line conductor providing and have square-section.
15. methods as claimed in claim 12, it is characterized in that, flexible line conductor is provided to provide flexible body line conductor, at least one in straight-line conductive path, arc conductive path, spiral conductive path and snakelike conductive path that the end that described line conductor is included in them links to make described line conductor comprise around axis winding multi-turn.
16. methods as claimed in claim 12, it is characterized in that, providing flexible line conductor to comprise provides the flexible line conductor with adhesive.
17. methods as claimed in claim 12, it is characterized in that, providing at least one prefabricated coil to comprise provides the multiple prefabricated coils being connected to lead frame.
18. the method for claim 1, is characterized in that, under the condition do not heated, stacked being performed as of described pressure makes not form physical clearance in described magnetic.
19. 1 kinds form power inductor by the method for claim 1.
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| US17526909P | 2009-05-04 | 2009-05-04 | |
| US61/175,269 | 2009-05-04 | ||
| CN2010800281522A CN102460613A (en) | 2009-05-04 | 2010-04-26 | Magnetic components and methods of manufacturing same |
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| CN2010800281522A Division CN102460613A (en) | 2009-05-04 | 2010-04-26 | Magnetic components and methods of manufacturing same |
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| CN2010800281522A Pending CN102460613A (en) | 2009-05-04 | 2010-04-26 | Magnetic components and methods of manufacturing same |
| CN201080028144.8A Expired - Fee Related CN102460612B (en) | 2009-05-04 | 2010-04-26 | Magnetic components and methods of manufacturing same |
| CN201080020152.8A Expired - Fee Related CN102428526B (en) | 2009-05-04 | 2010-04-27 | Surface mount magnetic components and methods of manufacturing the same |
| CN201080020154.7A Expired - Fee Related CN102428527B (en) | 2009-05-04 | 2010-04-28 | Surface mount magnetic components and methods of manufacturing the same |
| CN201080028165XA Pending CN102460614A (en) | 2009-05-04 | 2010-04-28 | Magnetic component assembly |
| CN201080020350.4A Expired - Fee Related CN102428528B (en) | 2009-05-04 | 2010-04-28 | The coil stacked for the low profile of magnet assembly and core |
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| CN2010800281522A Pending CN102460613A (en) | 2009-05-04 | 2010-04-26 | Magnetic components and methods of manufacturing same |
| CN201080028144.8A Expired - Fee Related CN102460612B (en) | 2009-05-04 | 2010-04-26 | Magnetic components and methods of manufacturing same |
| CN201080020152.8A Expired - Fee Related CN102428526B (en) | 2009-05-04 | 2010-04-27 | Surface mount magnetic components and methods of manufacturing the same |
| CN201080020154.7A Expired - Fee Related CN102428527B (en) | 2009-05-04 | 2010-04-28 | Surface mount magnetic components and methods of manufacturing the same |
| CN201080028165XA Pending CN102460614A (en) | 2009-05-04 | 2010-04-28 | Magnetic component assembly |
| CN201080020350.4A Expired - Fee Related CN102428528B (en) | 2009-05-04 | 2010-04-28 | The coil stacked for the low profile of magnet assembly and core |
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| EP (7) | EP2427893B1 (en) |
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